Unit:II “Spur Gears and Parallel Axis Helical Gears”

Design Procedure for Spur Gears

1. Calculation of gear ratio

From page no: 8.6
𝑁1 𝑧2
𝑖= =
𝑁2 𝑧1
𝑁1 , 𝑧1 - Speed, No of teeth of driving gear
𝑁2, 𝑧2 - Speed, No of teeth of driven gear

2. Selection of Materials
Choose the suitable material for pinion and
wheel from PSG Data book page no: 1.40, 8.4,
8.5 using the i value.
If the pinion and wheel are same design
only for pinion.
If they are made of different material
design for both pinion and wheel.
Most cases C45 for pinion and C.I grade
20 for wheel (If material is not specified)
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

3. Gear Life
Calculate the gear life based on given data.
Gear life in (hours)
Gear life in (min)
Life in number of cycles = (gear life in min) x N
N- speed of gear
If gear life is not specified assume it as 20,000
hrs

4. Calculation of design torque [mt]

From Page No: 8.15 – Table: 13
Design torque [Mt] = Mt k kd
60 𝑃
Mt=
2𝜋𝑁
Initially assume (k kd)= 1.3

5. Calculation of Eeq ,[b] ,[ c]

Calculation of Req
From page no. 8.14, Table: 9 for the given gear
material choose Equivalent young's modulus
(kgf/cm2)
Convert the unit to N/mm2
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

Calculation of [b]-Design bending stress

From page no:8.18, Table:18, assuming the
rotation is in one direction unless specified,
choose the formula.

Select the kbl value from page no:8.20, Table:22

Select the n value from page no:8.19, Table:20

 Unit:II “Spur Gears and Parallel Axis Helical Gears”

Select the k value from page no:8.19, Table:21;

assuming addendum modification factor as 0.

Select the - 1 value from page no:8.19, Table:19

based on the material.

Calculate - 1 value in kgf/cm2 and then convert

it to N/mm2

Select the u value from page no:8.5, Table:7

Convert the
unit to
kgf/cm2
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

Calculation of [ c]
From Page no: 8.16, Table:15; based on the
available data for the gear material select the
formula for design contact stress

Select CR or CB Valve based on the material and

its properties From page no: 8.16, table:16

Select the life factor kcl based on the material

and its properties from page no:8.17, Table :17
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

6. Calculation of centre distance

From Page no: 8.13

Assume the value of  from Page no: 8.14 (or

take it as 0.3)

7. Selection of z1,z2
If the number of teeth is not provided
Assume z1=17 for 20 pressure angle
Assume z1=32 for 141/2 pressure angle
Calculate the value for z2
𝑧2
𝑖=
𝑧1

8. Calculation for module

From Page no 8.22, Table:26

From Page no:8.2, Table 1; choose the std value

of module
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

9. Revision of centre distance

From Page no: 8.22,Table 26; calculate the new
centre distance

10. Calculation of b, d1, , p

Face width
From Page no: 8.1
b=  a
Pitch diameter of pinion
From Page no: 8.22, Table:26
d 1= m z 1

Pitch line velocity

𝜋𝑑𝑁
𝜐=
60
Calculation of p
From Page no: 8.15, Table:14
𝑏
p =
𝑑1
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

11. Selection of Quality of Gear

From Page no: 8.3, table:2
Form the calculated pitch line velocity choose
the IS quality of gear

12. Revision of design torque

Revised [Mt]
From Page no:8.15
Design torque [Mt] = Mt k kd
60 𝑃
Mt=
2𝜋𝑁
Use the revised k kd values

Revised k
From Page no:8.15 for the p value choose k
value
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

Revised kd
From Page No:8.16 using the IS quality, pitch line
velocity and surface hardness value choose kd

13. Check for bending

Calculation for induced bending stress
From Page no: 8.13A

The value of b (induced bending stress) should

be less than [b] (design bending stress) then
the design is safe

From page no:8.18 – Table 18; for the number of

teeth z1 value and assuming X as 0, choose the y
(form factor) value
 Unit:II “Spur Gears and Parallel Axis Helical Gears”

14. Check for wear strength

Calculation for induced contact stress
From Page no: 8.13

The value of c (induced contact stress) should

be less than [c] (design contact stress) then
the design is safe

15. Calculation of basic dimensions of

pinion and gear
Calculate the following values from Page no: 8.22; Table:26
Module (m)
Face width (b)
Height factor (f0)
Bottom clearance (c)
Tooth depth (h)
Pitch circle diameter (d1,d2)
Tip diameter (da1,da2)
Root diameter (df1,df2)

16. Check for wheel

If the material for wheel is different then this step is
needed
• Calculate N2
• Gear life based on N2
• Calculate the design values of [b] ,[ c] for wheel
• Calculate the induced values of b , c for wheel
• Verify that the wheel design is safe
• Then calculate the basic dimensions of wheel